Cylinder head installation (RZ4E-TC)

1) Clean the upper surface of the cylinder block and lower surface of the cylinder head using a scraper.

2) Prepare a cylinder head gasket with the same grade as the removed gasket.

3) Apply ThreeBond 1207B or equivalent to the positions on the cylinder block shown in the diagram.

Standard value

a: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height

b: 3.0 to 4.0 mm { 0.118 to 0.157 in } Bead width

4) Place the cylinder head gasket on the cylinder block.

5) Align the dowel positions, and place the cylinder head on the cylinder block.

6) Apply engine oil to the following locations.

7) Tighten the cylinder head bolts to the cylinder head using the special tool and a torque wrench in the order shown in the diagram.

SST: 5-8840-0266-0 - angle gauge

Tightening torque: 115 N・m { 11.7 kgf・m / 85 lb・ft } 1st time

Tightening torque: 115 N・m { 11.7 kgf・m / 85 lb・ft } 2nd time

Tightening Angle : 90 to 120 ° 3rd time

Tightening Angle : 90 to 120 ° 4th time

8) Install the bolts to the flywheel housing in the order shown in the diagram.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

9) Install the following parts to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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10) Apply LOCTITE 262 to the threaded portion of the plug.

11) Install the plug to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

12) Connect the connector to the CMP sensor.

1) Install the dowel pin to the cylinder head.

2) Check that the inlet camshaft and the exhaust camshaft notches are aligned with the camshaft cap alignment marks.

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3) Confirm that the 4 gaskets are installed to the lower surface of the camshaft carrier.

4) Referring to the diagram, apply ThreeBond 1207B to the cylinder head.

Standard value

a: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead width

b: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height

5) Apply engine oil to the threaded portions and seating surfaces of the bolts.

6) Temporarily tighten the camshaft carrier to the cylinder head in the order shown in the diagram.

7) Check that the camshaft carrier has been seated on the cylinder head.

8) Final tighten the camshaft carrier to the cylinder head in the order shown in the diagram.

Tightening torque: 7.0 N・m { 0.7 kgf・m / 62 lb・in }

9) Connect the vacuum hose to the vacuum pump.

10) Align the paint markings and install the timing chain to the camshaft sprocket.

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11) Install the timing chain tensioner and gasket to the flywheel housing.

Tightening torque: 70 N・m { 7.1 kgf・m / 52 lb・ft }

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12) Install the cam angle sensor rotor to the inlet camshaft.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Apply soapy water to the O-ring.

2) Install the thermostat housing to the cylinder head and front cover.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

3) Connect the connector to the engine coolant temperature sensor.

1) Install the bracket to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Install the turbocharger control solenoid valve to the bracket.

Tightening torque: 10 N・m { 1.0 kgf・m / 7 lb・ft }

3) Install the connector to the turbocharger control solenoid valve.

4) Connect the vacuum hose to the turbocharger control solenoid valve.

1) Install the common rail (fuel rail) to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Install the connector to the FRP sensor.

3) Install the bracket to the cylinder head.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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1) Install the fuel feed pipe to the fuel supply pump and common rail (fuel rail).

Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }

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2) Install the clip to the fuel feed pipe.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

1) Install the fuel leak-off pipe to the common rail (fuel rail) and flywheel housing.

Tightening torque: 20.2 N・m { 2.1 kgf・m / 15 lb・ft } Common rail (fuel rail) side

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Flywheel housing side

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2) Connect the fuel leak-off hose to the fuel leak-off pipe.

1) Install the gasket to the cylinder head.

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2) Referring to the diagram, temporarily tighten the exhaust manifold to the cylinder head.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft }

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3) Securely tighten the exhaust manifold to the cylinder head.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft } 1st time

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft } 2nd time

4) Install the heat protector to the exhaust manifold.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Install the water feed and return pipe, as well as the gasket to the turbocharger.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

2) Feed 1 cc (approximately 20 drops) of engine oil into the oil feed port.

3) Install the turbocharger and gasket to the exhaust manifold.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

1) Install the turbocharger heat protector to the turbocharger.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

1) Temporarily tighten the turbocharger bracket to the turbocharger and cylinder block in the order shown in the diagram.

2) Final tighten the turbocharger bracket to the turbocharger and cylinder block in the order shown in the diagram.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

1) Install the turbocharger oil pipe and gasket to the turbocharger.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

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2) Install the turbocharger oil pipe (feed side) to the cylinder block.

Tightening torque: 22.5 N・m { 2.3 kgf・m / 17 lb・ft } Eyebolt

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Bolt

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3) Install the turbocharger oil pipe (return side) and gasket to the cylinder block.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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1) Connect the turbocharger water return hose to the water feed pipe and return pipe.

2) Connect the turbocharger water feed hose to the water feed pipe and return pipe.

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Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter installation".

1) Install the vacuum hose to the turbocharger and vacuum pipe.

2) Connect the vacuum hose to the turbocharger control solenoid valve.

1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

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2) Connect the connector to the barometric pressure sensor.

3) Connect the connector to the MAF and IAT sensor.

1) Install the oil seal to the cylinder head cover.

2) Install the gasket to the camshaft carrier.

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3) Apply engine oil to the cylinder head cover O-ring.

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4) Referring to the diagram, apply ThreeBond 1207B to the cylinder head mating surface.

Standard value

b: 4.0 to 5.0 mm { 0.157 to 0.197 in } Bead width

c: 2.0 to 3.0 mm { 0.079 to 0.118 in } Bead height

Dimensions

a: 5.0 mm { 0.197 in }

5) Temporarily tighten the cylinder head cover to the cylinder head in the order shown in the diagram.

6) Final tighten the cylinder head cover to the cylinder head in the order shown in the diagram.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

7) Connect the harness clip to the cylinder head cover.

8) Connect the blow-by hose to the cylinder head cover.

1) Align the air duct with the air cleaner and turbocharger.

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2) Referring to the diagram, align the alignment mark positions and connect the air duct to the turbocharger.

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in }

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3) Install the PCV hose to the cylinder head cover and air duct.

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4) Install the intake air duct to the air cleaner and radiator core support.

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1) Clean the injector bracket mounting bolt holes using an air blower.

2) Clean the cylinder head installation surface and injector.

3) Install the gasket to the injector.

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4) Install the injector to the cylinder head.

5) Apply engine oil to the following locations.

6) Install the injector clamp to the injector.

Tightening torque: 38 N・m { 3.9 kgf・m / 28 lb・ft }

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7) Install the injector leak-off pipe to the injector.

8) Install the clips to the injector.

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9) Connect the injector leak-off hose to the injector leak-off pipe and fuel leak-off pipe.

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10) Connect the connector to the injector.

1. When replacing the injector

Erase the old cylinder number ID code on the Injector ID Code label attached to the cylinder head cover with a black pen, etc.

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1) Record the Injector ID Code of the new injector.

The correct order of the ID codes shown in the following injector illustration is as follows.
95 04 F9 F8 F0 00 F0 E7 09 F6 F9 96

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1) Temporarily tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the diagram.

2) Final tighten the injection pipes to the injectors and common rail (fuel rail) in the order shown in the diagram.

Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) inlet cover installation".